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US20080236724A1 - Method for manufacturing honeycomb structure - Google Patents

Method for manufacturing honeycomb structure Download PDF

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Publication number
US20080236724A1
US20080236724A1 US12/040,516 US4051608A US2008236724A1 US 20080236724 A1 US20080236724 A1 US 20080236724A1 US 4051608 A US4051608 A US 4051608A US 2008236724 A1 US2008236724 A1 US 2008236724A1
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US
United States
Prior art keywords
molded body
honeycomb
spacer
honeycomb molded
center
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/040,516
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English (en)
Inventor
Koji Higuchi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ibiden Co Ltd
Original Assignee
Ibiden Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ibiden Co Ltd filed Critical Ibiden Co Ltd
Assigned to IBIDEN CO., LTD. reassignment IBIDEN CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HIGUCHI, KOJI
Publication of US20080236724A1 publication Critical patent/US20080236724A1/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/248—Supports for drying
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • C04B38/0016—Honeycomb structures assembled from subunits
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B25/00—Details of general application not covered by group F26B21/00 or F26B23/00
    • F26B25/06—Chambers, containers, or receptacles
    • F26B25/14—Chambers, containers, receptacles of simple construction
    • F26B25/18—Chambers, containers, receptacles of simple construction mainly open, e.g. dish, tray, pan, rack
    • F26B25/185—Spacers; Elements for supporting the goods to be dried, i.e. positioned in-between the goods to build a ventilated stack
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F27—FURNACES; KILNS; OVENS; RETORTS
    • F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
    • F27D5/00—Supports, screens or the like for the charge within the furnace
    • F27D5/0031—Treatment baskets for ceramic articles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F26—DRYING
    • F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
    • F26B2210/00—Drying processes and machines for solid objects characterised by the specific requirements of the drying good
    • F26B2210/02—Ceramic articles or ceramic semi-finished articles

Definitions

  • the present invention relates to a method for manufacturing a honeycomb structure.
  • particulates such as soot in exhaust gases discharged from internal combustion engines of vehicles such as buses and trucks, and construction machines have raised serious problems as contaminants harmful to the environment and the human body.
  • a honeycomb structure of this kind there is employed a round pillar-shaped honeycomb structure having a plurality of rectangular pillar-shaped honeycomb fired bodies bonded together by interposing a sealing material layer (adhesive layer) to be manufactured by carrying out extrusion-molding, degreasing, firing treatments, and the like on a mixture comprising a ceramic material such as silicon carbide.
  • a sealing material layer adheresive layer
  • a honeycomb fired body can be manufactured by using, for example, the following method.
  • a raw material composition is prepared by mixing a ceramic material such as silicon carbide, a binder, a dispersant solution and the like, and after this raw material composition has been continuously extrusion-molded, a molded body thus extruded is cut into a predetermined length so that a rectangular pillar-shaped honeycomb molded body is manufactured.
  • a ceramic material such as silicon carbide, a binder, a dispersant solution and the like
  • the obtained honeycomb molded body is dried by using a microwave drying apparatus or a hot-air drying apparatus; then, after predetermined cells have been sealed so that either one of the ends of each cell has been sealed, the honeycomb molded body undergoes a degreasing treatment.
  • honeycomb fired body can be manufactured through the processes.
  • the firing treatment among the above-mentioned processes refers to a treatment for manufacturing a honeycomb fired body by heating at a high temperature a honeycomb molded body, which is manufactured through extrusion-molding, and in which an organic matter is removed through the degreasing treatment, and by sintering ceramic powder.
  • firing treatment was carried out with the honeycomb molded body placed on a bottom plate of a firing jig made of carbon.
  • JP-A 2001-220240 1 and JP-A 2001-72472 disclose a method for firing a silicon carbide molded body (honeycomb molded body) in which firing is carried out with a space provided between a bottom plate of a firing jig and the silicon carbide molded body.
  • FIG. 8 is a cross-sectional view schematically showing a method for disposing spacers on a surface of a firing jig, placing a honeycomb molded body on the spacers, and carrying out a firing treatment thereon.
  • spacers 12 made of a ceramic material such as carbon are disposed on a bottom plate 11 of a firing jig 10 , and a honeycomb molded body 120 is placed on the spacers 12 , and the firing treatment is carried out with a space having the same thickness as the thickness of each of the spacers 12 is provided between the bottom plate 11 of the firing jig 10 and the honeycomb molded body 120 .
  • JP-A 2001-72472 discloses a firing jig having a protruding portion.
  • JP-A 2001-220240 and JP-A 2001-72472 are incorporated herein by reference in their entirety.
  • a method for manufacturing a honeycomb structure of the present invention includes manufacturing a pillar-shaped honeycomb molded body having a large number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween, carrying out a firing treatment on the honeycomb molded body with the honeycomb molded body placed on a spacer disposed on a bottom plate of a firing jig to manufacture a honeycomb fired body, and bonding a plurality of the honeycomb fired bodies together by interposing an adhesive layer to manufacture a honeycomb aggregated body.
  • the spacer is disposed on at least two locations so that a center of gravity of the honeycomb molded body is sandwiched in the longitudinal direction. Further, the spacer is disposed with respect to each of middle points between the center of gravity of the honeycomb molded body and centers of gravity of each of end faces of the honeycomb molded body so as to include both an area on a side of the center of gravity and an area on a side of each of the end faces, of the honeycomb molded body, upon each of the middle points being used as reference standard. Each of the end faces is an end face in a longitudinal direction of the honeycomb molded body.
  • FIG. 1 is a perspective view schematically showing one example of a honeycomb structure
  • FIG. 2A is a perspective view schematically showing honeycomb fired body forming the honeycomb structure shown in FIG. 1
  • FIG. 2B is a cross-sectional view taken along line A-A of FIG. 2A ;
  • FIG. 3A is a partially cut-out perspective view schematically showing a method for placing honeycomb molded bodies in a firing jig in the first embodiment of the present invention
  • FIG. 3B is a plan view of a portion shown by B in FIG. 3A ;
  • FIG. 4A and FIG. 4B are plan views schematically each showing a positional relationship between spacers and a honeycomb molded body in the respective Examples.
  • FIG. 5A , FIG. 5B , FIG. 5C and FIG. 5D are plan views schematically each showing a positional relationship between a honeycomb molded body and spacers in the respective Comparative Examples;
  • FIG. 6 is a plan view schematically showing a positional relationship between spacers and a honeycomb molded body in the second embodiment
  • FIG. 7 is a plan view schematically showing a positional relationship between spacers and a honeycomb molded body in the third embodiment
  • FIG. 8 is a cross-sectional view schematically showing a method for disposing spacers on a surface of a firing jig, placing a honeycomb molded body on the spacers, and carrying out a firing treatment thereon;
  • FIG. 9 is a cross-sectional view schematically showing a way in which the vicinity of a center of gravity of a honeycomb molded body placed on spacers sinks and warps;
  • FIG. 10 is a partially cut-out perspective view schematically showing one example of a method for disposing spacers just under centers of gravity of each of honeycomb molded bodies in a firing treatment and placing the honeycomb molded bodies in a firing jig;
  • FIG. 11 is a cross-sectional view schematically showing a way in which the vicinity of a center of gravity of a honeycomb molded body placed on spacers is lifted up and warps.
  • a honeycomb molded body made of silicon carbide as a ceramic material contains about 3% of SiO 2 in a silicon carbide powder resulting from the manufacturing conditions, sublimated and discharged, a portion thereof became SiO gas, the reaction proceeded in which the SiO gas reacted with the carbon forming the firing jig to generate SiC, and coarse particles of silicon carbide may be formed on the bottom plate of the firing jig.
  • the firing jig is a member designed for repetitive use. There is a problem that when placing the honeycomb molded body on the bottom plate of the firing jig with coarse particles of silicon carbide formed thereon and carrying out a firing treatment on the honeycomb molded body, the surface of the honeycomb molded body is susceptible to damage, and pinholes and cracks occur in the obtained honeycomb fired body, likely leading to strength reduction of the honeycomb fired body.
  • JP-A 2001-220240 it is estimated that carrying out the firing treatment with a space provided between the bottom plate 11 of the firing jig 10 and the honeycomb molded body 120 enables prevention of formation of coarse particles of silicon carbide on the bottom plate 11 of the firing jig 10 and prevention of occurrence of cracks and pinholes in a honeycomb fired body to be manufactured.
  • Placement of a silicon carbide molded body (honeycomb molded body) on the protruding portion of the firing jig according to JP-A 2001-72472 enables a space having the same thickness as the thickness of the protruding portion to be provided between a bottom plate of the firing jig and the honeycomb molded body.
  • FIG. 9 is a cross-sectional view schematically showing a way in which the vicinity of a center of gravity of a honeycomb molded body placed on spacers sinks and warps.
  • honeycomb fired bodies upon manufacturing a honeycomb structure formed by bonding a plurality of honeycomb fired bodies each having warpage, there is a problem that the honeycomb fired bodies sometimes make contact with one another and crack in bonding, leading to difficulty in manufacturing the honeycomb structure.
  • occurrence of warpage resulting from sinking of the vicinity of the center of gravity of the honeycomb molded body in the firing treatment is substantially prevented by disposing a spacer also just under the honeycomb molded body in addition to two spacers shown in FIG. 9 .
  • FIG. 10 is a partially cut-out perspective view schematically showing one example of a method for disposing a spacer just under a center of gravity of each of honeycomb molded bodies in a firing treatment and placing the honeycomb molded bodies in a firing jig.
  • a portion of a side wall member of the firing jig is omitted so that it may be easier to seize the placement state of the honeycomb molded bodies.
  • a firing jig 10 is designed to give a length of one side of the bottom plate of the firing jig 10 slightly larger than a longitudinal length of a honeycomb molded body 120 to be placed.
  • honeycomb fired bodies in which warpage occurred are not appropriate for manufacturing a honeycomb structure, there remained a problem that the vicinity of the center of gravity was lifted up.
  • FIG. 11 is a cross-sectional view schematically showing a way in which the vicinity of a center of gravity of a honeycomb molded body placed on spacers is lifted up and warps.
  • warpage of a firing jig also causes warpage of a honeycomb fired body.
  • a method for manufacturing a honeycomb structure is a method for manufacturing a honeycomb structure, including the steps of: manufacturing a pillar-shaped honeycomb molded body having a large number of cells disposed in parallel with one another in a longitudinal direction with a cell wall therebetween; carrying out a firing treatment on the honeycomb molded body with the honeycomb molded body being placed on a spacer disposed on a bottom plate of a firing jig to manufacture a honeycomb fired body; and bonding a plurality of the honeycomb fired bodies together by interposing an adhesive layer to manufacture a honeycomb aggregated body by, in the firing treatment, when the honeycomb molded body placed on the spacer is viewed in a plan view, the spacer being disposed on at least two locations so that a center of gravity of the honeycomb molded body is sandwiched in the longitudinal direction, the spacer being disposed with respect to each of middle points between the center of gravity of the honeycomb molded body and centers of gravity of each of end faces of the honeycomb
  • the spacers are disposed on at least two locations so as to sandwich a center of gravity of the honeycomb molded body in a longitudinal direction in the firing treatment.
  • the spacers are disposed in such a manner, since the spacers are not disposed in the vicinity of the center line of the bottom plate of the firing jig, that is, just under the center of gravity of the honeycomb molded body. Thus, less force tends to be applied in a direction in which the honeycomb molded body is lifted up by interposing the spacers even in the case where the vicinity of the center of the bottom plate of the firing jig is lifted up. Therefore, it becomes easier to reduce warpage that will occur in a honeycomb fired body along a direction in which the bottom plate of the firing jig warps.
  • the spacer is disposed with respect to each of middle points between the center of gravity of the honeycomb molded body and centers of gravity of each of end faces of the honeycomb molded body so as to include both an area on a side of the center of gravity of the honeycomb molded body and an area on a side of each of the end faces, upon each of the middle points being used as reference standard, provided that each of the end faces is an end face in a longitudinal direction of the honeycomb molded body.
  • honeycomb fired bodies do not contact each other or cause cracks. Accordingly, it becomes easier to manufacture the honeycomb structure with improved yield.
  • a distance between the two spacers across the center of gravity is at least about 25% and at most about 45% of a length in a longitudinal direction of the honeycomb fired body.
  • the embodiment of the present invention by setting a distance between the two spacers to the range, it becomes easier to more effectively exert both the effect of minimizing the force to be applied in the direction in which the honeycomb molded body sinks due to its own weight and the effect of minimizing warpage that will occur along the direction in which the bottom plate of the firing jig will warp. Accordingly, it becomes easier manufacture a honeycomb fired body with smaller warpage.
  • the spacer is disposed on a location overlapped with each of the middle points.
  • a single spacer can be disposed so as to include both an area on a side of the center of gravity of the honeycomb fired body and an area on a side of one of the end faces, upon a single middle point being used as reference standard.
  • a length in the longitudinal direction of the spacer overlapped with the middle point is at least about 20 mm and at most about 50 mm.
  • the length of the spacer in the longitudinal direction of the honeycomb molded body is set to about 20 mm or more, a distance between a side of the spacers closest to the center of gravity of the honeycomb molded body and the center of gravity of the honeycomb molded body and a distance between a side of the spacers closest to each of the end faces of the honeycomb molded body and each of the end faces of the honeycomb molded body are made shorter, it becomes easier to reduce the force to be applied to the vicinity of both the center of gravity and the end face of the honeycomb molded body. Accordingly, it becomes easier to manufacture a honeycomb fired body with smaller warpage.
  • firing may be insufficient on an area where the spacer contacts the honeycomb molded body, the insufficient firing may tend to lower strength of the honeycomb fired body.
  • the length of the spacer in the longitudinal direction of the honeycomb molded body is about 50 mm or less, it becomes easier to reduce the size of an area where the spacer contacts the honeycomb molded body and firing is insufficient, and consequently to manufacture a honeycomb fired body with higher strength more easily.
  • the spacers are disposed so that each of the middle points is sandwiched between at least two spacers where a center side spacer is disposed in an area on a side of the center of gravity of the honeycomb molded body and an end face side spacer of the honeycomb molded body is disposed in an area on a side of an end face, upon each of the middle points being used as reference standard.
  • the spacers are disposed, with respect to a single middle point, on both a side of the center of gravity and a side of each of the end faces, of the honeycomb molded body, upon the single middle point being used as reference standard.
  • the surface of the honeycomb fired body after fired tends to become rough (become a state having projections and depressions).
  • firing since firing is carried out very sufficiently, it becomes easier to manufacture a honeycomb fired body with the smooth surface of an area that the spacer has contacted.
  • a distance between a location closest to the center of gravity of the end face of the end face side spacer and a location closest to the center of gravity of the center side spacer is at least about 30 mm and at most about 50 mm.
  • a distance between a location closest to the center of gravity of the end face of said end face side spacer and a location closest to the center of gravity of the center side spacer is at least about 9% and at most about 16% of a length in a longitudinal direction of the honeycomb fired body.
  • lengths in the longitudinal direction of the end face side spacer and the center side spacer are at least about 5 mm and at most about 10 mm.
  • the honeycomb molded body is more likely to be misaligned upon placing the honeycomb molded body on the spacer in the firing jig.
  • the length in the longitudinal direction of the spacer is set to about 5 mm or more, it becomes easier to prevent misalignment of the honeycomb molded body.
  • the length in the longitudinal direction of the spacer is set to about 10 mm or less, it becomes easier to further reduce the size of an area where the honeycomb molded body contacts the spacer. Accordingly, it becomes easier to manufacture a honeycomb fired body with higher strength and with the smooth surface of an area that the spacer has contacted (not in a state having projections and depressions).
  • the spacer in the firing treatment, when the honeycomb molded body placed on the spacer is viewed in a plan view, the spacer is disposed on a location axisymmetric with respect to a line, the line passing through a center of gravity of the honeycomb molded body and being perpendicular to the longitudinal direction.
  • the embodiment of the present invention it is possible to more easily distribute, in a balanced manner, the force applied to the vicinity of the center of gravity of the honeycomb molded body and the vicinity of each of the end faces thereof. Accordingly, it becomes easier to manufacture a honeycomb fired body with smaller warpage and higher dimensional accuracy.
  • a length in a longitudinal direction of the honeycomb molded body is about 305 mm or more.
  • the embodiment of the present invention it becomes easier to manufacture a honeycomb fired body with smaller warpage and higher strength even in the case where the honeycomb molded body has a longer length, and consequently to manufacture a honeycomb structure with improved yield more easily.
  • the honeycomb molded body is manufactured by molding a raw material composition including at least silicon carbide powder and a binder.
  • a honeycomb fired body shown in FIG. 2A and FIG. 2B and a honeycomb structure shown in FIG. 1 are manufactured.
  • FIG. 1 is a perspective view schematically showing one example of an embodiment of a honeycomb structure
  • FIG. 2A is a perspective view schematically showing a honeycomb fired bodies forming the honeycomb structure shown in FIG. 1
  • FIG. 2B is a cross-sectional view taken along line A-A of FIG. 2A .
  • a plurality of honeycomb fired bodies 110 are bound together by interposing an adhesive layer 101 to form a ceramic block 103 , and a coat layer 102 is formed on the periphery of the ceramic block 103 .
  • a large number of cells 111 are disposed in parallel with one another in a longitudinal direction (a direction shown by an arrow a in FIG. 2A ) so that cell walls 113 partitioning the cells 111 are allowed to function as filters.
  • end face of the honeycomb fired body refers to faces at which cells are exposed among the faces forming the outer shape of the honeycomb fired body, while the term “side face” refers to all faces that are not end faces.
  • the ends of either an exhaust gas inlet side or an exhaust gas outlet side of the cells 111 formed in the honeycomb fired body 110 is sealed with a plug material layer 112 . Therefore, the exhaust gas that enters one cell 111 will always pass through the cell wall 113 partitioning the cells 111 to flow out through another one of the cells 111 . When the exhaust gas passes through the cell wall 113 , particulates contained within the exhaust gas are captured by the cell wall 113 , to thereby purify the exhaust gas.
  • FIG. 3A is a partially cut-out perspective view schematically showing a method for placing honeycomb molded bodies in a firing jig in the first embodiment
  • FIG. 3A is a plan view of the portion shown by B in FIG. 3A .
  • a portion of a side wall member of the firing jig is omitted so that it may be easier to seize the placement state of the honeycomb molded body.
  • FIG. 3B shows a view rotated by 90 degrees relative to FIG. 3A so that the longitudinal direction of the honeycomb molded body is a direction horizontal to the paper surface.
  • a firing jig 10 shown in FIG. 3A is made of carbon and has a box shape with its upper surface open.
  • the box shape is made of a rectangular plate-shaped bottom plate 11 and a side wall member 13 vertically installed on four sides of the bottom plate 11 .
  • the dimension of the firing jig is designed so that a length of the shorter side of the bottom plate 11 is slightly longer than a length in the longitudinal direction of the honeycomb molded body 120 .
  • two spacers 12 for placing the honeycomb molded body 120 are disposed on a location axisymmetric with respect to a center line that passes through a middle point of the shorter side of the bottom plate 11 .
  • the spacer 12 is made of carbon felt formed by combining carbon fibers into a cloth-like shape, has a thickness of at least about 2.0 mm and at most about 5.0 mm, and has a length of the shorter side of at least about 20 mm and at most about 50 mm. A length of the longer side of the spacer 12 is slightly shorter than a length of the longer side of the bottom plate 11 of the firing jig 10 .
  • two spacers 12 are disposed on the bottom plate 11 , and the honeycomb molded body 120 is placed so as to give a predetermined positional relationship with the two spacers 12 .
  • FIG. 3B is a plan view of the portion shown by B in FIG. 3A .
  • the honeycomb molded body has a rectangular pillar shape whose both end faces are an almost square shape, the center of gravity of the left side end face LG of the honeycomb molded body 120 serves as the middle point of the line segment that shows the left side end face 125 , and the center of gravity of the right side end face RG serves as the middle point of the line segment that shows the right side end face 126 .
  • the middle points between the center of gravity of the left side end face LG or the center of gravity of the right side end face RG, and the center of gravity G, of the honeycomb molded body 120 serves as the left side middle point L and the right side middle point R, respectively, of the honeycomb molded body 120 .
  • the honeycomb molded body 120 is placed on two spacers 12 so that one of the two spacers 12 is overlapped with the left side middle point L and the other spacer 12 is overlapped with the right side middle point R, when the honeycomb molded body 120 placed on the spacers 12 , as shown in FIG. 3B , is viewed in a plan view.
  • the spacers When the spacers are overlapped with each of the two middle points, the spacers are disposed with respect to each of the middle points L or R so as to include both an area on a side of the center of gravity and an area on a side of each of the end faces, of the honeycomb molded body 120 .
  • the positional relationship between the honeycomb molded body 120 and the two spacers 12 is determined so that the spacers 12 are disposed on a location axisymmetric with respect to a line M that passes through the center of gravity G of the honeycomb molded body and is perpendicular to the longitudinal direction thereof.
  • the positional relationship between the honeycomb molded body 120 and the two spacers 12 is determined so that the center of gravity G of the honeycomb molded body 120 is sandwiched between the two spacers 12 in the longitudinal direction of the honeycomb molded body 120 .
  • a length of the spacer 12 in the longitudinal direction of the honeycomb molded body 120 refers to a length shown by W in FIG. 3B , and the length W is equal to a length of the shorter side of the spacer and is at least about 20 mm and at most about 50 mm.
  • the length W is referred to as a length W of the spacer in the longitudinal direction or a length W.
  • the distance between the two spacers 12 refers to a distance shown by E in FIG. 3B and is at least about 25% and at most about 45% of the length in the longitudinal direction of the honeycomb molded body 120 .
  • the distance E is defined as a proportion (%), to the full length of the honeycomb molded body, of the distance E between: 14 L that is on the line passing through the center of gravity of the left side end face LG and the center of gravity G of the honeycomb molded body and that is closest to the center of gravity G of the spacer 12 overlapped with the middle point L; and 14 R that is on the line passing through the center of gravity of the right side end face RG and the center of gravity G of the honeycomb molded body and that is closest to the center of gravity G of the spacer 12 overlapped with the middle point R.
  • the distance E (%) is referred to as a distance E between spacers or a distance E.
  • a mixed powder is prepared by dry mixing a raw material composition such as silicon carbide powder having different average particle diameters from each other and an organic binder, and a mixed liquid is prepared by mixing a liquid plasticizer, a lubricant and water. Subsequently, the mixed powder and the mixed liquid are mixed with a wet mixer to prepare a wet mixture for manufacturing a molded body.
  • a rectangular pillar-shaped honeycomb molded body shown in FIG. 2A is manufactured by cutting, with a cutting apparatus, the long honeycomb molded body obtained through extrusion-molding.
  • the honeycomb molded body is cut so that a length in the longitudinal direction of the honeycomb molded body is about 305 mm or more.
  • the honeycomb molded body is dried using a drying apparatus combining microwaves and hot air.
  • the ends of the outlet sides of the inlet side cell group and the ends of the inlet sides of the outlet side cell group are filled with a predetermined amount of plug material paste, which is to be the plug, and then the cells are sealed.
  • a sealing mask is first applied to the end faces (the cut faces after the cutting) of the honeycomb molded body, and thereafter the plug material paste is injected only to the cells that needs sealing.
  • honeycomb molded body filled with plug material paste is manufactured through the processes.
  • the honeycomb molded body filled with plug material paste is placed on the spacers in the firing jig so that the honeycomb molded body may have the above-mentioned positional relationship with the spacer, and degreasing is carried out at a degreasing temperature of at least about 250° C. and at most about 390° C. in a degreasing furnace with an oxygen concentration of at least about 5% and at most about 13% by volume in the atmosphere, so that organic substances contained in the honeycomb molded body were removed.
  • a firing treatment was carried out at about 2200° C., for example, in an argon atmosphere for 3 hours to manufacture a honeycomb fired body.
  • sealing material paste to form an adhesive layer is applied to side faces of the obtained honeycomb fired body so that a sealing material paste layer is formed, and lamination of another honeycomb fired body on the sealing material paste layer is sequentially repeated, and bonding is carried out to manufacture an honeycomb aggregated body with a predetermined number of honeycomb fired bodies being bonded together.
  • the sealing material paste include a substance containing an inorganic binder, an organic binder, and at least one of inorganic fibers and inorganic particles.
  • the honeycomb aggregated body is heated for drying and solidifying an adhesive paste layer to form an adhesive layer.
  • cutting is carried out on the honeycomb aggregated body by using a diamond cutter to form a ceramic block, sealing material paste is applied to the outer periphery of the ceramic block, and the sealing material paste is dried and solidified to form a coat layer, so that the manufacturing of the honeycomb structure is completed.
  • sealing material paste used for formation of the adhesive layer and the coat layer the same or different sealing material paste may be used.
  • the spacers are disposed with respect to each of the two middle points between the center of gravity of the honeycomb molded body and centers of gravity of each of the end faces of the honeycomb molded body so as to be present on a side of each of the end faces of the honeycomb molded body, upon each of the middle points being used as reference standard, and it is possible to reduce the force to be applied to the vicinity of each of the end faces of the honeycomb molded body. Accordingly, it becomes easier to manufacture a honeycomb fired body with small warpage.
  • a distance between the two spacers across the center of gravity of the honeycomb molded body is set to at least about 25% and at most about 45% of a length in a longitudinal direction of the honeycomb fired body, it becomes easier to exert both the effect of minimizing the force to be applied in the direction in which the honeycomb molded body sinks due to its own weight and the effect of minimizing warpage that will occur along the direction in which the bottom plate of the firing jig will warp. Accordingly, it becomes easier to manufacture a honeycomb fired body with smaller warpage.
  • a single spacer can be disposed so as to include both an area on a side of the center of gravity of the honeycomb fired body and an area on a side of one of the end faces, upon a single middle point being used as reference standard. Accordingly, it becomes easier to manufacture a honeycomb fired body with small warpage.
  • the length of the spacer in the longitudinal direction of the honeycomb molded body is set to about 20 mm or more, a distance between a side of the spacers closest to the center of gravity of the honeycomb molded body and the center of gravity of the honeycomb molded body and a distance between a side of the spacers closest to each of the end faces of the honeycomb molded body and each of the end faces of the honeycomb molded body are made shorter, it becomes easier to reduce the force to be applied to the vicinity of both the center of gravity and the end face of the honeycomb molded body. Accordingly, it becomes easier to manufacture a honeycomb fired body with small warpage.
  • the length W of the spacer in the longitudinal direction of the honeycomb molded body is set to about 50 mm or less, it becomes easier to reduce the size of an area where the spacer contacts the honeycomb molded body. Accordingly, it becomes easier to manufacture a honeycomb fired body having higher strength after sufficient firing.
  • a honeycomb molded body having a shape shown in FIG. 2A and FIG. 2B is manufactured by cutting the extrusion-molded honeycomb molded body with a cutting member installed in a cutting apparatus.
  • the honeycomb molded body had a size of 33.0 mm ⁇ 33.0 mm ⁇ 330.2 mm.
  • the honeycomb molded body was dried using a drying apparatus combining microwaves and hot air, and subsequently the plug material paste having the same composition as the composition used for extrusion-molding was injected to prescribed cells.
  • two spacers made of carbon felt (shorter side 20 mm ⁇ longer side 410 mm ⁇ thickness 5 mm) were disposed on a box-shaped firing jig made of a porous carbon (G100, manufactured by Tokai Carbon, Co., Ltd.) with one of its principal surface open (shorter side of the bottom plate 350 mm ⁇ longer side of the bottom plate 430 mm ⁇ height 45 mm), and three honeycomb molded bodies were placed on the two spacers at regular intervals so that the longitudinal direction of each of the honeycomb molded bodies is perpendicular to longer sides of the spacers.
  • a box-shaped firing jig made of a porous carbon (G100, manufactured by Tokai Carbon, Co., Ltd.) with one of its principal surface open (shorter side of the bottom plate 350 mm ⁇ longer side of the bottom plate 430 mm ⁇ height 45 mm)
  • FIG. 4A and FIG. 4B are plan views schematically each showing a positional relationship between spacers and a honeycomb molded body in the respective Examples.
  • the length W is a length of the shorter side of the spacer 12 , that is, 20 mm, and the distance E between the spacers is 43.9% of the full length of the honeycomb molded body.
  • the firing jig with the honeycomb molded body placed thereon was transported into a continuous-type degreasing furnace, and a degreasing treatment was carried out by heating at 400° C. in a mixed gas atmosphere of air having an oxygen concentration of 9% by volume and nitrogen.
  • the degreased honeycomb molded body was transported into a firing apparatus, and a firing treatment was carried out at 2200° C. in a normal-pressure argon atmosphere for 3 hours to manufacture a honeycomb fired body in a square pillar shape.
  • FIG. 5A , FIG. 5B , FIG. 5C and FIG. 5D are plan views schematically each showing a positional relationship between spacers and a honeycomb molded body and in the respective Comparative Examples.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that in the degreasing treatment and the firing treatment, as shown in FIG. 5A , each of the spacers was disposed on a location where each of the end faces of the honeycomb molded body was overlapped with a longer side of each of the spacers so that the spacer was located only on a side of each of the end faces, upon the middle point L or R being used as reference standard.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that in the degreasing treatment and the firing treatment, as shown in FIG. 5B , in addition to the two spacers disposed on the same locations as in Comparative Example 1, one spacer was further disposed so that the center of gravity G was overlapped with the spacer.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that in the degreasing treatment and the firing treatment, as shown in FIG. 5C , one spacer was disposed on a location where an end face of the honeycomb molded body was overlapped with a longer side of the spacer so that the one spacer was located only on a side of the end face, upon the middle point L being used as reference standard, and the other spacer was disposed so that the middle point R was overlapped with the spacer.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that in the degreasing treatment and the firing treatment, as shown in FIG. 5D , in addition to the two spacers disposed on the same locations as in Example 1, one spacer was further disposed so that the center of gravity G was overlapped with the spacer.
  • honeycomb fired body was manufactured in the same manner as in Example 1, except that in the degreasing treatment and the firing treatment, the honeycomb molded body was placed directly on the bottom plate of the firing jig without disposing spacers.
  • Measurement of the warpage amount was made using a warpage amount measurement jig.
  • a straight rectangular block made of SUS and having a length of almost the same as the full length of the molded body is used, and contact members of identical thickness are disposed on both ends of the block.
  • a scale which is slidable in the direction perpendicular to the longitudinal direction of the block, is installed at the center of the block.
  • a bending strength tester (Instron 5582) was used to conduct a four-point bending strength test on randomly selected honeycomb fired bodies (5 samples) by applying a load of 51 MPa, with an upper span distance of 195 mm and a lower span distance of 308 mm, and at a speed of 0.35 mm/min, to determine whether cracks occurred on the respective honeycomb fired bodies.
  • the span distance and load were calculated so that a stress was set to 30 MPa based on geometrical moment of inertia upon consideration of a length of the molded body, a thickness of cell walls, and cell density.
  • Table 1 shows the results, provided that the case where cracks did not occur in any of the five samples is indicated by “++”, the case where cracks occurred in any of the five samples is indicated by “+”, the case where cracks occurred in all of the five samples is indicated by “ ⁇ ”.
  • JIS-R-1624 The content of JIS-R-1624 is incorporated herein by reference in its entirety.
  • the obtained honeycomb fired body was visually evaluated for appearance of an area that contacted the spacer in the firing treatment.
  • Table 1 shows the results provided that the case where the surface of the area was smooth is indicated by “+++”, and the others are indicated by “++”, “+”, and “ ⁇ ” based on the order of how less rough the surface of the area is.
  • Example 1 since a firing treatment was carried out so that the spacers were disposed so as to be overlapped with each of the two middle points, the obtained honeycomb fired body had a small warpage of 0.8 mm or less.
  • Example 1 the honeycomb fired body obtained in Example 1 had sufficient bending strength. This has revealed that according to the method in Example 1 it is possible to manufacture a preferable honeycomb fired body for manufacturing a honeycomb structure.
  • each of the honeycomb fired bodies obtained in Comparative Examples 1 to had a large warpage of more than 1.0 mm, and was a honeycomb fired body not appropriate for manufacturing a honeycomb structure. The warpage occurred presumably because the location of the spacer was not appropriate or the spacer was not used.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that in the degreasing treatment and the firing treatment, the spacer having a length of the shorter side of 30 to 50 mm and having the length W (30 to 50 mm) shown in Table 2 was disposed.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that in the degreasing treatment and the firing treatment, the spacer having a length of the shorter side of 10 mm, or 60 mm to 90 mm, and having the length W (10 mm, or 60 mm to 90 mm) shown in Table 2 was disposed.
  • honeycomb fired bodies obtained in the respective Examples and Reference Examples were evaluated for warpage amount and fired state.
  • Table 2 shows the results, as well as the results of Example 1.
  • FIG. 4(a) yes yes 10 46.9 330.2 0.8 to 1.0 ++ ++ Example 1
  • FIG. 4(a) yes yes 20 43.9 330.2 0.5 to 0.8 ++ ++
  • the manufactured honeycomb fired body had a very small warpage of 0.5 mm or less.
  • the obtained honeycomb fired body had satisfactory bending strength.
  • the distance E varies as the length W varies. Warpage was low, that is, 0.8 mm or less, when the distance E was in the range of about 25 to about 45% as in the case of Examples 1 to 4 and Reference Examples 2 to 4.
  • honeycomb fired body was manufactured in the same manner as in Example 1, except that the honeycomb molded body having a length in the longitudinal direction of 355.6 mm was manufactured by changing the cutting dimension upon cutting the extrusion-molded honeycomb molded body.
  • honeycomb fired body was manufactured in the same manner as in Example 1, except that the honeycomb molded body having a length in the longitudinal direction of 304.8 mm was manufactured by changing the cutting dimension upon cutting the extrusion-molded honeycomb molded body.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that the honeycomb molded body having a length in the longitudinal direction of 304.8 mm was manufactured by changing the cutting dimension upon cutting the extrusion-molded honeycomb molded body, and that in the firing treatment, as shown in FIG. 5( a ), each of the spacers was disposed on a location where each of the end faces of the honeycomb molded body was overlapped with a longer side of each of the spacers so that the spacer was located only on a side of each of the end faces, upon the middle point L or R being used as reference standard.
  • honeycomb fired bodies obtained in the respective Examples, Reference Examples, and Comparative Examples were evaluated for warpage amount and fired state.
  • Table 3 shows the results, as well as the results of Example 1 and Comparative Example 1.
  • FIG. 4(a) yes yes 20 43.5 304.8 0.5 to ++ ++ Example 6 0.8
  • FIG. 4(a) yes yes 20 43.9 330.2 0.5 to ++ ++ 0.8
  • the obtained honeycomb fired body had a warpage of 1.0 mm or less, not so large a value, when a length of the molded body was less than 305 mm; on the other hand, the obtained honeycomb fired body had a warpage of more than 1.0 mm, when a length of the molded body was about 305 mm or more.
  • the present Reference Example had a structure in which the spacers disposed were not axisymmetric with respect to a line that passes through the center of gravity of the honeycomb molded body and is perpendicular to the longitudinal direction.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that a length of the shorter side of the spacer was changed.
  • honeycomb fired bodies obtained in the Reference Example were evaluated for warpage amount and fired state.
  • Table 4 shows the results, as well as the results of Example 1.
  • Example 1 As is clear from the results in Table 4, smaller warpage was observed in Example 1 in comparison with Reference Example 7. This is presumably because in Example 1 the spacer was disposed on a location axisymmetric with respect to a line that passes through the center of gravity of the honeycomb molded body and is perpendicular to the longitudinal direction.
  • the positional relationship between the spacer and the honeycomb molded body is determined so that the spacer is overlapped with each of the two middle points; instead of the positional relationship, the positional relationship between the spacer and the honeycomb molded body is determined so that each of the middle points are not overlapped with the spacer, and each of the middle points is sandwiched between at least two spacers (a center side spacer and an end face side spacer) that are located on a side of the center of gravity of the honeycomb molded body and on a side of an end face, upon each of the middle points being used as reference standard.
  • spacers a center side spacer and an end face side spacer
  • FIG. 6 is a plan view schematically showing a positional relationship between spacers and a honeycomb molded body in the second embodiment.
  • the spacer used in the present embodiment is the same as the spacer used in the first embodiment, and it is possible to preferably use the spacer having a width of at least about 5 mm and at most about 10 mm.
  • a honeycomb molded body 120 is placed on four spacers 32 , as shown in FIG. 6 .
  • a center side spacer 32 G exists on a side of the center of gravity G
  • an end face side spacer 32 E exists on a side of the center of gravity of a left side end face LG
  • the left side middle point L is sandwiched between the two spacers 32 .
  • the center side spacer 32 G exists on a side of the center of gravity G
  • the end face side spacer 32 E exists on a side of the center of gravity of a right side end face RG
  • the right side middle point R is sandwiched between the two spacers 32 .
  • the distance between the location 35 L and the location 34 L is a distance indicated by D in FIG. 6 .
  • each of the spacers 32 is positioned so that the distance D is set to at least about 30 mm and at most about 50 mm.
  • each of the spacers 32 is positioned so that the distance D is set to at least about 30 mm and at most about 50 mm.
  • each of the spacers is positioned so that the distance D is set to at least about 9% and at most about 16% of the longitudinal direction of the honeycomb molded body.
  • the distance D is represented as a length (mm) or as a proportion (%) of the distance D to the length of the longitudinal direction of the honeycomb molded body.
  • a distance E between spacers is defined as a proportion (%) of the distance between the location 34 L and the location 34 R to the full length of the honeycomb molded body.
  • each of the spacers 32 is positioned so that the distance E is set to at least about 25% and at most about 45%.
  • a length W refers to a length of the shorter side, that is, at least about 5 mm and at most about 10 mm.
  • the distance D is set to about 30 mm (about 9%) or more, it becomes easier to shorten a distance between a side of the spacers closest to the center of gravity of the honeycomb molded body and the center of gravity of the honeycomb molded body and a distance between a side of the spacers closest to each of the end faces of the honeycomb molded body and each of the end faces of the honeycomb molded body, it becomes easier to reduce the force to be applied to the vicinity of both the center of gravity and the end face of the honeycomb molded body.
  • the distance D is set to about 50 mm (about 16%) or less, it becomes easier to shorten a distance between a side of the spacers closest to the middle point and the middle point. Accordingly, it becomes easier to reduce the force to be applied in the direction in which the vicinity of the middle point sandwiched between two spacers is to sink.
  • the length W of the spacer in the longitudinal direction is set to about 10 mm or less, it becomes easier to markedly reduce the size of an area where the spacer contacts the honeycomb molded body. Accordingly, it becomes easier to manufacture a honeycomb fired body with higher strength and with the smooth surface of an area where the spacer has contacted the honeycomb molded body.
  • the honeycomb molded body is more likely to be misaligned upon placing the honeycomb molded body on the spacer in the firing jig.
  • the length in the longitudinal direction of the spacer is set to about 5 mm or more, it becomes easier to prevent misalignment of the honeycomb molded body.
  • the spacers were disposed so that each of the middle points L and R were sandwiched between two spacers that were located on a side of the center of gravity and on a side of each of the end faces, of the honeycomb molded body, upon each of the middle points being used as reference standard, and so that the distance D was set to 50 mm.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that the spacers were thus disposed.
  • honeycomb fired bodies obtained in the Example were evaluated for warpage amount and fired state.
  • Table 5 shows the results, as well as the results of Example 4.
  • Example 6 since spacers were disposed so that each of the two middle points L and R were sandwiched between two spacers, the obtained honeycomb fired body had small warpage.
  • the manufactured honeycomb fired body had very small warpage of 0.5 mm or less.
  • Example 6 results of Example 6 are compared with the results of Example 4.
  • the distance D was 50 mm in Example 6 while the length W was 50 mm in Example 4.
  • honeycomb molded body had a very small warpage of 0.5 mm or less in both of the Examples. This is presumably because in both of the Examples, the spacers were present on both sides of the two middle points, and a distance between a side of the spacers closest to the center of gravity of the honeycomb molded body and the center of gravity of the honeycomb molded body and a distance between a side of the spacers closest to each of the end faces of the honeycomb molded body and each of the end faces of the honeycomb molded body were made shorter.
  • Example 6 appearance was more satisfactory in Example 6. This is presumably because firing was carried out more sufficiently in Example 6 since an area where the spacers contacted the honeycomb molded body was smaller in Example 6 than that in Example 4.
  • a honeycomb fired body was manufactured in the same manner as in Example 6, except that in the degreasing treatment and the firing treatment, the location of the spacer was changed, and that the spacers were disposed, as shown in Table 6, so that the distance D was set to 20 to 60 mm (6 to 18%) and the distance E was set to 43.9 to 31.8%.
  • honeycomb fired bodies obtained in the respective Examples and Reference Examples were evaluated for warpage amount and fired state.
  • Table 6 shows the results, as well as the results of Example 6.
  • FIG. 6 yes yes 5 20 mm, 43.9 330.2 0.5 to 0.8 ++ +++ Example 8 6%
  • Example 9 18%
  • the manufactured honeycomb fired body had a small warpage of 0.5 mm or less.
  • a honeycomb fired body was manufactured in the same manner as in Example 6, except that in the degreasing treatment and the firing treatment, the spacers were disposed so that the length of the shorter side was set to 3 to 12 mm and the length W was set to the length shown in Table 7 (3 to 12 mm).
  • the spacers were disposed so that the distance D was set to 50 mm (15%) and the distance E was set to 34.8%.
  • honeycomb fired bodies obtained in the Example and each of the Reference Examples were evaluated for warpage amount and fired state.
  • Table 7 shows the results, as well as the results of Example 6.
  • the manufactured honeycomb fired body had a small warpage of 0.5 mm or less, higher bending strength, and very satisfactory appearance. This is presumably because an area where the spacer contacted the honeycomb molded body was so small that firing was carried out sufficiently. In addition, this is presumably because the spacer does not bite into the honeycomb molded body.
  • spacers are disposed also on locations where the spacers are overlapped with each of the two middle points.
  • FIG. 7 is a plan view schematically showing a positional relationship between spacers and a honeycomb molded body in the third embodiment.
  • the honeycomb molded body 120 is not placed on six spacers 32 , as shown in FIG. 7 .
  • a center side spacer 32 G is present on a side of the center of gravity G and an end face side spacer 32 E is present on a side of the center of gravity of a left side end face LG, upon a left side middle point L as well being reference standard, the left side middle point L is sandwiched between the two spacers 32 .
  • a spacer 32 is present also on a location overlapped with the left side middle point L.
  • a center side spacer 32 G is present on a side of the center of gravity G and an end face side spacer 32 E is present on a side of the center of gravity of the right side end face RG, upon a right side middle point R being reference standard, and furthermore, a spacer 32 is present also on a location overlapped with the right side middle point R.
  • spacers were disposed so that each of the middle points L and R is sandwiched between two spacers 32 (a center side spacer and an end face side spacer) that were located on a side of the center of gravity and on a side of each of the end faces, of the honeycomb molded body, upon each of the middle points being used as reference standard, and each of the middle points L and R is overlapped with the spacer 32 .
  • the spacers were disposed in this case so that the distance D was set to 50 mm (15%) and the distance E was set to 34.8%.
  • a honeycomb fired body was manufactured in the same manner as in Example 1, except that the spacers were thus disposed.
  • honeycomb fired bodies obtained in the Example were evaluated for warpage amount and fired state.
  • Table 8 shows the results, as well as the results of Examples 4 and 6.
  • Example 10 since a firing treatment was carried out with spacers disposed so that each of the two middle points was sandwiched between two spacers and each of the two middle points is overlapped with the spacers, the obtained honeycomb fired body had small warpage.
  • the honeycomb molded body had a very small warpage of 0.5 mm or less.
  • Example 10 were approximately the same as the results of Example 6, and appearance in Example 10 were more satisfactory than that in Example 4. This is presumably because firing was carried out more sufficiently in Example 10 as well since an area where the spacer contacted the honeycomb molded body is smaller in Example 10 than that in Example 4.
  • the material of the spacers is not particularly limited as long as the material can bear high temperature during firing, and thus it is possible to preferably use the ceramic member having heat resistance.
  • the spacers desirably have high thermal conductivity in order to rapidly progress the sintering of the honeycomb molded body.
  • examples of the ceramic member include carbon, silicon carbide, aluminum nitride, silicon nitride, and the like.
  • carbon felt formed by combining carbon fibers into a cloth-like shape, and a ceramic member formed by weaving linear carbon fibers are preferable. This is because since these are not too solid, it is less likely to damage the honeycomb molded body.
  • a bulk density of the carbon felt is desirably about 0.3 g/cm 3 or less, and more desirably about 0.1 g/cm 3 or less. This is because when the bulk density is within the range, the honeycomb molded body is not damaged, a contact area between the honeycomb molded body and the carbon felt is small, and furthermore since an SiO gas generated from the honeycomb molded body passes through the carbon felt, coarse particles made of silicon carbide are less likely to be formed due to the reaction between the honeycomb molded body and the carbon felt.
  • a thickness of the spacer is desirably about 1.0 mm or more upon consideration of a space between the firing jig and the honeycomb molded body to be provided, and desirably about 10.0 mm or less upon consideration of thermal conduction to the honeycomb molded body.
  • a specific shape of the spacer is not particularly limited, and a square pillar shape is desirable in terms of stability upon placement of the honeycomb molded body.
  • the honeycomb structure to be manufactured in the present embodiment is not limited to a honeycomb structure with the cells being sealed.
  • a honeycomb structure with the cells being sealed can be preferably used as a honeycomb filter; whereas a honeycomb structure with the cells not being sealed can be preferably used as a catalyst supporting carrier.
  • the main component of the constituent material of the honeycomb structure is not limited to silicon carbide, and other examples of ceramic materials include inorganic powder such as nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, titanium nitride; carbide ceramics such as zirconium carbide, titanium carbide, tantalum carbide, tungsten carbide; and oxide ceramics such as alumina, zirconia, cordierite, mullite, and aluminum titanate, and the like.
  • nitride ceramics such as aluminum nitride, silicon nitride, boron nitride, titanium nitride
  • carbide ceramics such as zirconium carbide, titanium carbide, tantalum carbide, tungsten carbide
  • oxide ceramics such as alumina, zirconia, cordierite, mullite, and aluminum titanate, and the like.
  • non-oxide ceramics are preferable, and silicon carbide is more preferable because these are excellent in thermal resistance properties, mechanical strength, and thermal conductivity.
  • examples of the constituent material of the honeycomb structure also include silicon-containing ceramic, in which metallic silicon is blended with the ceramics set forth above, as well as a ceramic material such as ceramic bound by silicon or silicate compounds. And out of these, those ceramics (silicon-containing silicon carbide) in which metallic silicon is blended with silicon carbide are preferably used.
  • the particle diameter of the silicon carbide powder is not particularly limited, and the silicon carbide powder that tends not to cause the case where the size of the honeycomb structure manufactured by the following firing treatment becomes smaller than that of the honeycomb molded body after degreased is preferable.
  • the organic binder in the wet mixture is not particularly limited, and examples thereof include methylcellulose, carboxy methylcellulose, hydroxy ethylcellulose, polyethylene glycol, and the like. Methylcellulose is desirable among these.
  • a blending amount of the organic binder is desirably at least about 1 parts by weight and at most about 10 parts by weight with respect to 100 parts by weight of inorganic powder.
  • the plasticizer in the wet mixture is not particularly limited, and examples thereof include glycerin and the like.
  • the lubricant is not particularly limited, and examples thereof include polyoxyalkylene-based compounds such as polyoxyethylene alkyl ether and polyoxypropylene alkyl ether, and the like. Specific examples of the lubricant include polyoxyethylene monobutyl ether, polyoxypropylene monobutyl ether, and the like.
  • the plasticizer and the lubricant may not be contained in the mixed raw material powder in some cases.
  • a dispersant solution may be used upon preparing a wet mixture, and examples of the dispersant solution include water, an organic solvent such as benzene, alcohol such as methanol, and the like.
  • a molding aid may be added to the wet mixture.
  • the molding aid is not particularly limited, and examples thereof include ethylene glycol, dextrin, fatty acid, fatty acid soap, polyalcohol, and the like.
  • a pore-forming agent such as balloons that are fine hollow spheres including oxide-based ceramics, spherical acrylic particles, and graphite may be added to the wet mixture, if necessary.
  • the balloon is not particularly limited, and examples thereof include alumina balloon, glass micro balloon, shirasu balloon, fly ash balloon (FA balloon), mullite balloon and the like.
  • Alumina balloon is desirable among these.
  • a wet mixture prepared here, in which silicon carbide powder is used desirably has a temperature of about 28° C. or less. The reason for this is that when the temperature is too high, an organic binder may gel.
  • a proportion of organic component in the wet mixture is desirably 10% by weight or less, and a content of water in the wet mixture is desirably at least about 8% by weight and at most about 20% by weight.
  • the plug material paste for sealing the cells is not particularly limited, a plug to be manufactured through the subsequent processes desirably has a porosity of at least about 30% and at most about 75%, and for example, it is possible to use a plug material paste having the same composition as that of the wet mixture.
  • the gaps between the honeycomb fired bodies may be collectively filled in with the sealing material paste after a necessary number of honeycomb fired bodies are assembled together through the spacer.
  • Examples of the inorganic binder in the sealing material paste include silica sol, alumina sol, and the like. Each of these materials may be used alone, or two or more kinds of these may be used in combination. Silica sol is desirable among the inorganic binders.
  • Examples of the organic binder in the sealing material paste include polyvinyl alcohol, methyl cellulose, ethyl cellulose, carboxymethyl cellulose, and the like. Each of these may be used alone or two or more kinds of these may be used in combination. Carboxymethyl cellulose is desirable among the organic binders.
  • Examples of the inorganic fibers in the sealing material paste include ceramic fibers and the like such as silica-alumina, mullite, alumina, and silica. Each of these may be used alone or two or more kinds of these may be used in combination. Alumina fibers are desirable among the inorganic fibers.
  • Examples of the inorganic particles in the sealing material paste include carbides, nitrides, and the like, and specific examples thereof include inorganic powder or the like made from silicon carbide, silicon nitride and boron nitride. Each of these may be used alone, or two or more kinds of these may be used in combination. Out of the inorganic particles, silicon carbide is desirably used due to its superior thermal conductivity.
  • a pore-forming agent such as balloons that are fine hollow spheres comprising oxide-based ceramics, spherical acrylic particles, and graphite may be added to the sealing material paste, if necessary.
  • the balloons are not particularly limited, and examples thereof include alumina balloons, glass micro-balloons, shirasu balloons, fly ash balloons (FA balloons), mullite balloons, and the like.
  • Alumina balloons are more desirably used among these.
  • drying treatment After manufacturing a honeycomb molded body through extrusion-molding, it is not always necessary to carry out a drying treatment, but as needed. In addition, the drying treatment may be performed after filling ends of cells with a plug material paste.
  • a microwave drying apparatus when the drying treatment is carried out on the honeycomb molded body, a microwave drying apparatus, a hot air drying apparatus, a reduced pressure drying apparatus, a dielectric drying apparatus, a freeze drying apparatus, or the like, in addition to a drying apparatus combining microwave and hot air, may be used.
  • the honeycomb structure thus completed can be suitably used as a catalyst supporting carrier for supporting a catalyst.
  • a firing jig different from a firing jig used during the firing treatment may be used during the degreasing treatment.
  • a catalyst may be supported on the honeycomb structure manufactured in the embodiment of the present invention if necessary.
  • a catalyst may be supported on a honeycomb fired body before manufacturing a honeycomb aggregated body.
  • an alumina film (layer) having a high specific surface area is formed on the surface of the honeycomb structure, and a co-catalyst, and a catalyst such as platinum are applied onto the surface of the alumina film.
  • Examples of the method for forming the alumina film on the surface of the honeycomb structure include: a method in which the honeycomb structure is impregnated with a solution of a metal compound containing aluminum such as Al(NO3)3 and then heated; a method in which the honeycomb structure is impregnated with a solution containing alumina powder and then heated; and the like.
  • Examples of the method for applying a co-catalyst include a method in which the honeycomb structure is impregnated with a solution of a metal compound containing a rare-earth element such as Ce(NO3)3 and then heated, and the like.
  • Examples of the method for applying a catalyst to the alumina film include a method in which the honeycomb structure is impregnated with a solution of diamine dinitro platinum nitric acid ([Pt(NH3)2(NO2)2]HNO3, platinum concentration: about 4.53% by weight) and the like and then heated, and the like.
  • a solution of diamine dinitro platinum nitric acid [Pt(NH3)2(NO2)2]HNO3, platinum concentration: about 4.53% by weight
  • a catalyst may be applied by a method in which, after preceding application of a catalyst to alumina particles, the honeycomb structure is impregnated with a solution containing alumina powder with the catalyst applied thereto, and then heated.

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US12/040,516 2007-03-30 2008-02-29 Method for manufacturing honeycomb structure Abandoned US20080236724A1 (en)

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US20090252906A1 (en) * 2008-03-24 2009-10-08 Ibiden Co., Ltd. Honeycomb structure and method for manufacturing honeycomb structure
US20090242100A1 (en) * 2008-03-27 2009-10-01 Ibiden Co., Ltd. Method for manufacturing honeycomb structure
WO2014143367A1 (en) * 2013-03-13 2014-09-18 Rolls-Royce Corporation Component including structures for determinant loading
US9631916B2 (en) 2013-03-13 2017-04-25 Rolls Royce Corporation Component including structures for determinant loading
CN113008002A (zh) * 2021-02-25 2021-06-22 吴小平 一种轴承浸泡后风力驱动式晾干机构
US12420469B2 (en) * 2022-03-31 2025-09-23 Ngk Insulators, Ltd. Method for manufacturing cylindrical honeycomb fired body

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